Manufacturing of parallel wire cable

ABSTRACT

A preassembled parallel wire cable creates a random cast of loops. Any of the random cast of loops is hung for transport, thus eliminating costly and time-consuming coiling and reeling operations.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation of U.S. application Ser. No.16/454,182 filed Jun. 27, 2019 and since issued as U.S. Pat. No.10,962,145, which is continuation of U.S. application Ser. No.16/185,049 filed Nov. 9, 2018 and since issued as U.S. Pat. No.10,376,051, which is continuation of U.S. application Ser. No.15/656,151 filed Jul. 21, 2017 and since issued as U.S. Pat. No.10,149,536, which is continuation of U.S. application Ser. No.14/283,292 filed May 21, 2014 and since issued as U.S. Pat. No.9,743,764, with all patent applications incorporated herein by referencein their entireties. This patent application also relates to U.S. patentapplication Ser. No. 13/084,693 filed Apr. 12, 2011 and to U.S. patentapplication Ser. No. 13/946,133 filed Jul. 19, 2013, with both patentapplications also incorporated herein by reference in their entireties.

BACKGROUND

Parallel wire cables have long been desired as structural components.Parallel wire cables, though, twist and coil, making handling andtransportation difficult and even unsafe. Conventional manufacturingtechniques, then, coil the wire cables, which greatly increases theircosts.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The features, aspects, and advantages of the exemplary embodiments arebetter understood when the following Detailed Description is read withreference to the accompanying drawings, wherein:

FIGS. 1 and 2 are schematics illustrating a few operating environments,according to exemplary embodiments;

FIGS. 3-5 are more detailed schematics illustrating a structural cable,according to exemplary embodiments;

FIG. 6 is a schematic illustrating prefabrication and preassembly of aparallel wire cable, according to exemplary embodiments;

FIG. 7 is a schematic illustrating a memory cast of a preassembledparallel wire cable, according to exemplary embodiments;

FIGS. 8-10 are schematics illustrating a transportation rack, accordingto exemplary embodiments;

FIGS. 11-12 are schematics illustrating transport of multiplepreassembled parallel wire cables, according to exemplary embodiments;

FIG. 13 is a schematic illustrating sequential racking of thepreassembled parallel wire cables, according to exemplary embodiments;

FIG. 14 is a schematic illustrating removal of the preassembled parallelwire cables, according to exemplary embodiments;

FIG. 15 is a schematic illustrating straightening and reeling of aparallel wire cable, according to exemplary embodiments;

FIG. 16 is a schematic illustrating an additional twisting operation ofa parallel wire cable, according to exemplary embodiments, and

FIG. 17 is a flowchart illustrating a method of transporting thepreassembled parallel wire cable, according to exemplary embodiments.

DETAILED DESCRIPTION

The exemplary embodiments will now be described more fully hereinafterwith reference to the accompanying drawings. The exemplary embodimentsmay, however, be embodied in many different forms and should not beconstrued as limited to the embodiments set forth herein. Theseembodiments are provided so that this disclosure will be thorough andcomplete and will fully convey the exemplary embodiments to those ofordinary skill in the art. Moreover, all statements herein recitingembodiments, as well as specific examples thereof, are intended toencompass both structural and functional equivalents thereof.Additionally, it is intended that such equivalents include bothcurrently known equivalents as well as equivalents developed in thefuture (i.e., any elements developed that perform the same function,regardless of structure).

Thus, for example, it will be appreciated by those of ordinary skill inthe art that the diagrams, schematics, illustrations, and the likerepresent conceptual views or processes illustrating the exemplaryembodiments. Those of ordinary skill in the art further understand thatthe exemplary cables described herein are for illustrative purposes and,thus, are not intended to be limited to any particular manufacturingprocess and/or manufacturer.

As used herein, the singular forms “a,” “an,” and “the” are intended toinclude the plural forms as well, unless expressly stated otherwise. Itwill be further understood that the terms “includes,” “comprises,”“including,” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,elements, components, and/or groups thereof. It will be understood thatwhen an element is referred to as being “connected” or “coupled” toanother element, it can be directly connected or coupled to the otherelement or intervening elements may be present. As used herein, the term“and/or” includes any and all combinations of one or more of theassociated listed items.

It will also be understood that, although the terms first, second, etc.may be used herein to describe various elements, these elements shouldnot be limited by these terms. These terms are only used to distinguishone element from another.

FIGS. 1 and 2 are schematics illustrating a few operating environments,according to exemplary embodiments. FIG. 1 illustrates a suspensionbridge 10 having a deck 12 supported by one or more pillars 14 (or“towers”) and by a structural cable 16. The structural cable 16 anchorsat opposite ends 18 and 20 by structural anchors 22. Tension in thestructural cable 16 helps support the weight of the deck 12. As thefollowing paragraphs will explain, exemplary embodiments preassemble thestructural cable 16. That is, the structural cable 16 may bemanufactured off-site and then transported to the suspension bridge 10for installation. The structural cable 16 may thus be preassembled in acontrolled and safe environment, which greatly reduces the costs of thesuspension bridge 10.

FIG. 2 illustrates another operating environment. Here the structuralcable 16 supports a generally vertical structure 30. The verticalstructure 30 is illustrated as a wind turbine 32, but the verticalstructure 30 may be any apparatus (such as a drilling rig, antenna, ortower for utility cables and lines). The structural cable 16 stays, orstabilizes, the vertical structure 30. Again, because the structuralcable 16 may be manufactured off-site and then transported to the joblocation, exemplary embodiments greatly reduce the costs of the verticalstructure 30.

FIGS. 3-5 are more detailed schematics illustrating the structural cable16, according to exemplary embodiments. FIG. 3, for simplicity, onlyillustrates a short, longitudinal portion 38 of the structural cable 16.As the reader may understand, the structural cable 16 can be very long,perhaps hundreds or even thousands of feet in length. FIG. 3 thus onlyillustrates a cross-sectional portion to better illustrate itsprefabricated construction. The structural cable 16 has a plurality 40of wires. The plurality 40 of wires is illustrated as a bundle 42 havinga circular shape 44. The plurality 40 of wires, however, may be bundledin any cross-sectional shape desired (such as hexagonal, triangular, orsquare). Each individual wire 46 in the plurality 40 of wires may beconstructed of any metallic and/or non-metallic material. An individualwire 46, for example, may be a five (5) or seven (7) millimeter diametersteel wire (or any other diameter or gauge wire suitable for structuralcable). Any of the individual wires 46, however, may be constructed fromany metallic material (such as aluminum or copper), carbon fibermaterial, and/or composite material. Each individual wire 46 isillustrated as having a circular cross-sectional shape, but any of thewires 46 may have any other cross-sectional shape (such as hexagonal,triangular, polygonal, or even a variable cross-sectional shape).

FIG. 4 illustrates a parallel construction. The individual wires 46 aresubstantially parallel to each other. Because the structural cable 16may be hundreds or thousands of feet in length, FIG. 4 omits a centralsection for ease of illustration. Regardless, each wire 46 in theplurality 40 of wires is parallel to every other wire 46. The structuralcable 16, then, is a parallel wire cable 50, where the individual wires46 are parallel along their entire length L (illustrated as referencenumeral 52) from the one end 18 to the opposite end 20. Each wire 46 inthe plurality 40 of individual wires may also be equal in length 52 toevery other wire 46. Each wire 46 in the parallel wire cable 50, inother words, may be parallel to, and equal in length 52 to, every otherwire 46. Because each wire 46 is parallel to every other wire 46, nowinding operation is required. The parallel wire cable 50, in otherwords, need not be spirally or helically wound.

FIG. 5 illustrates individual tensioning. Exemplary embodiments apply atension value T (illustrated as reference numeral 60) to each wire 46 inthe parallel wire cable 50. In practice there may be many, evenhundreds, of the individual wires 46 in the parallel wire cable 50. FIG.5, though, only illustrates a few wires 46 in the parallel wire cable 50to simplify explanation. Each wire 46 in the plurality 40 of individualwires may have an equal, or nearly equal, tension to every other wire 46in the parallel wire cable 50. The tension value 60 is applied to oneindividual wire 62 of the individual wires 46. An end 64 of theindividual wire 62 is mechanically locked, held, or secured in a firstfixture 66. An opposite end 68 of the individual wire 62 is then drawnor pulled to the desired tension value 60. When the desired tensionvalue 60 is attained, the opposite end 68 of the individual wire 62 isthen mechanically locked, held, or secured in a second fixture 70.

Pretensioning is repeated. Once the tension value 60 is applied to theindividual wire 62, then a different wire 80 is selected and the sametension value 60 is pulled. Afterwards yet another different wire 46 issequentially or randomly selected and pulled to the tension value 60.This pretensioning procedure is repeated until all the individual wires46 have been individually pulled to approximately the same tension value60. Each wire 46 in the plurality 40 of individual wires may thus havethe equal tension value 60 to every other wire 46 in the parallel wirecable 50.

Tension is applied to each wire 46, not strands of wires. Methods areknown that tension strands of plural wires. A strand, in the art ofstructural cable, is defined as a group of multiple wires. Conventionalmethods are known that apply tension to a strand of multiple wires.Exemplary embodiments, in contradistinction, apply the tension value 60to each individual wire 46 in the parallel wire cable 50. Each wire 46in the plurality 40 of individual wires has the equal tension value 60as every other wire 46 in the parallel wire cable 50.

Individual pretensioning of each wire 46 will provide lighter, cheaper,and stronger cable designs. The individually tensioned parallel wirecable 50 weighs significantly less than conventional designs, but thestrength of the parallel wire cable 50 is still greater thanconventional designs. Alternatively, exemplary embodiments may be usedto construct the parallel wire cable 50 that is similar in size toconventional designs, but is substantially stronger to support greaterloads and/or spans. Exemplary embodiments have greater tensile strength,greater compressive strength, greater yield strength, and substantiallyincreased fatigue life when compared to conventional designs, yetexemplary embodiments react the same as any steel member. Exemplaryembodiments thus offer greater design alternatives that require lessmaterial, production, and transportation costs.

FIG. 6 is a schematic illustrating prefabrication and preassembly of theparallel wire cable 50, according to exemplary embodiments. As thisdisclosure explains, exemplary embodiments individually pull each wire46 in the parallel wire cable 50. Physical testing shows that theresulting parallel wire cable 50 has a similar yield strength toconventional designs of many more wires. That is, exemplary embodimentsexhibit similar strength using fewer wires 46. The resulting parallelwire cable 50 thus has a smaller overall diameter, and less weight, thanconventional designs using many more wires. Material costs are thusgreatly reduced.

The parallel wire cable 50 may thus be prefabricated and preassembled.As this disclosure earlier explained, the individually tensionedparallel wire cable 50 may be prefabricated offsite in a shopenvironment, where temperature and other factors are better controlled.Once the plurality 40 of wires has been individually tensioned,exemplary embodiments may seize the parallel wire cable 50 with seizings90 to maintain the tension value 60 in each wire 46. The plurality 40 ofwires may then be cut to a desired overall length (illustrated asreference numeral 52 in FIG. 4). End attachments, known as sockets 92,may also be added to each end (e.g., illustrated as reference numerals18 and 20 in FIGS. 1 and 4) of the parallel wire cable 50. Because theparallel wire cable 50 is fabricated and assembled in the shopenvironment, exemplary embodiments allow preassembly withoutconventional aerial spinning at a construction site.

FIG. 7 is a schematic illustrating a memory cast of the preassembledparallel wire cable 50, according to exemplary embodiments. Once theparallel wire cable 50 is preassembled, the tension may be removed. Whenthe tension is released, though, the preassembled parallel cable 50 mayrandomly twist and turn in unpredictable directions. The preassembledparallel wire cable 50 thus assumes an intricate and confusingconfiguration creating a random cast 100 of loops. Curvature, or cast,in the individual wires (illustrated as reference numeral 46 in FIGS.3-5) causes the random cast 100 of loops. When each individual wire 46is manufactured at a foundry, each individual wire 46 has a curvature orcast (usually caused by coiling and reeling). Even though the individualwire 46 is then pulled straight to the tension value (as aboveexplained), once released the individual wire 46 has structural memoryand bends to return to its original shape. As there may be manyindividual wires 46 in the preassembled parallel wire cable 50, theindividual memories in the individual wires 46 unpredictably create therandom cast 100 of loops. Once the tension is released in the wires 46,then, the preassembled parallel wire cable 50 assumes the random cast100 of loops having various convex and concave inflections of differingradii, angle, and/or diameter that may easily tangle.

FIGS. 8-9 are schematics illustrating a transportation rack 110,according to exemplary embodiments. Even though the preassembledparallel wire cable 50 may exhibit the random cast 100 of loops, thepreassembled parallel wire cable 50 may be advantageously transportedwithout conventional coiling and reeling. Conventional manufacturingtechniques reel cables onto a large spool, and the spool is then loadedonto a trailer or boat for transport. An expensive coiling machine orprocess is thus conventionally used, which increases handling andtooling costs. Exemplary embodiments, instead, utilize the memory in therandom cast 100 of loops as a handling and transportation feature.Exemplary embodiments thus utilize the random cast 100 of loops to avoidand eliminate conventional coiling/reeling techniques.

As FIG. 8 illustrates, the preassembled parallel wire cable 50 is hungfrom the transportation rack 110. Even though the preassembled parallelcable 50 creates the random cast 100 of loops, exemplary embodimentsadvantageously use the random cast 100 of loops for transport. After theparallel wire cable 50 is preassembled, any of the random cast 100 ofloops may be hung from the rack 110. A human worker or lifting machineneed only grasp and hang one or more of the random cast 100 of loopsonto the rack 110. As FIG. 9 illustrates, the rack 110 may then be movedand loaded onto a trailer, ship, or barge for delivery to theinstallation site. Because the random cast 100 of loops is hung from therack 110, no coiling and reeling operation is needed. Exemplaryembodiments thus further reduce the costs of the preassembled parallelcable 50.

FIG. 10 is a more detailed schematic illustrating the transportationrack 110, according to exemplary embodiments. Here the transportationrack 110 may be adjustable to accommodate the unpredictable random cast100 of loops. Because the preassembled parallel cable 50 may randomlytwist and turn in unpredictable directions, workers cannot predict theconfiguration of the random cast 100 of loops. The transportation rack110 may thus include one or more means for adjusting its hangerconfiguration to suit the random cast 100 of loops.

The transportation rack 110 may have one or more arms 120. Each one ofthe arms 120 may laterally extend outward from a central beam 122. Thecentral beam 122 may be a hollow-walled tube, such as a steel square orround tube. Because the central beam 122 is hollow, the central beam 122may include one or more longitudinal slots 124 from which the arms 120protrude or insert. Each arm 120 may thus longitudinally slide along itscorresponding longitudinal slot 124. Each arm 120 may thus belongitudinally positioned along the central beam 122 to accommodate atleast one of the random cast 100 of loops. One or more upright supports126 elevate the central beam 122 to any desired height.

FIGS. 11-12 are schematics illustrating transport of multiplepreassembled parallel wire cables 50, according to exemplaryembodiments. Here the single transportation rack 110 may accommodatemultiple preassembled parallel wire cables 50. That is, multiplepreassembled parallel wire cables 50 may be racked or hung from the arms120 of the transportation rack 110. FIG. 11, for example, illustrates asecond preassembled parallel wire cable 130 and a third preassembledparallel wire cable 132 hanging from the arms 120 of the transportationrack 110. Indeed, as FIG. 12 illustrates, the single transportation rack110 may simultaneously hang many preassembled parallel wire cables 50.Additional arms 120 may outwardly extend from opposite sides of thecentral beam 120. The transportation rack 110 may thus be loaded on portand starboard sides with one or more days of production of thepreassembled parallel wire cables 50.

FIG. 13 is a schematic illustrating sequential racking of thepreassembled parallel wire cables 50, according to exemplaryembodiments. As the reader may envision, care may be needed when hangingthe multiple preassembled parallel wire cables 50. As the preassembledparallel cable 50 may randomly twist and turn in unpredictabledirections, one or more of the preassembled parallel wire cables 50 maybe easily tangled and even knotted. Damage and/or lost time may ensue,thus jeopardizing production efficiency.

Sequential racking may be desired. As FIG. 13 illustrates, once thepreassembled parallel wire cable 50 is ready for hanging, a worker mayfirst locate and hang a leading one 140 of the sockets 92. Thepreassembled parallel wire cable 50 may have an orientation identifiedby the leading socket 140. An opposite, trailing socket 142 readilyidentifies the other terminal end of the preassembled parallel wirecable 50. The leading socket 140 and the trailing socket 142 may beidentified to ensure the preassembled parallel wire cable 50 iscorrectly oriented for handling and/or for installation. The worker,then, may first locate and hang the leading socket 140 to a leading orfront end 144 of the transportation rack 110. That is, the leadingsocket 140 may be hung on or around a leading, first arm 146 of thetransportation rack 110. The worker may next locate and hang thetrailing socket 142 on or around a last, trailing arm 148 at a trailingor rear end 150 of the transportation rack 110. No matter how many arms122 may protrude from the transportation rack 110, this sequentialracking helps ensure the proper orientation is maintained and easilyidentified. After the leading socket 140 and the trailing socket 142 aresequentially hung, the worker may then proceed to hang any of the randomcast 100 of loops. No matter what the configuration of the random cast100 of loops, this sequential racking ensures the leading and trailingends of the proper orientation are maintained and identified.

Securements may be used. Once the worker hangs the preassembled parallelwire cable 50 to the rack 110, the leading socket 140 and the trailingsocket 142 may be secured to their corresponding arms 146 and 148. Anyof the random cast 100 of loops may also be secured to their respectivearms 122. Ties, hooks, bands, chain or rope may be quickly wrapped orwound around the preassembled parallel wire cable 50 to ensure thecorrect orientation is maintained during transport. Indeed, as the rack110 may be transported long distances across continents and/or oceans,any mechanical fastener, adhesive, or welding may be used to secure thepreassembled parallel wire cable 50 to the rack 110.

Sequential racking may repeat and continue. Once one preassembledparallel wire cable 50 is hung and secured to the rack 110, anotherpreassembled parallel wire cable 50 may be hung from the same rack 110.The leading socket 140 of the another preassembled parallel wire cable50 is hung to the leading, first arm 146 of the transportation rack 110.The opposite, trailing socket 142 is then hung to or around the last,trailing arm 148 of the transportation rack 110. The worker then hangsand secures any of the intervening random cast 100 of loops. Because thepreassembled parallel wire cables 50 are sequentially hung from theirleading socket 140, the possibility of entanglement is reduced or nearlyeliminated. The worker may thus sequentially hang as many preassembledparallel wire cables 50 as the transportation rack 110 may hold, usuallyup to some maximum capacity in total number or weight.

Transportation then occurs. Once the one or more preassembled parallelwire cables 50 are hung to the transportation rack 110, the rack 110 maybe loaded on a trailer, ship, or barge for transportation to aninstallation site. As FIG. 13 illustrates, the transportation rack 110may include lifting slots or passageways 160 for insertion of liftingforks. A common forklift may thus lift, move, and load thetransportation rack 110 onto any carrier's transport. No specializedand/or oversized transport is thus needed to deliver the preassembledparallel wire cables 50 to the installation site.

FIG. 14 is a schematic illustrating removal of the preassembled parallelwire cables 50, according to exemplary embodiments. Once thetransportation rack 110 is delivered to the installation site, thepreassembled parallel wire cables 50 are easily removed from thetransportation rack 110. Because the preassembled parallel wire cables50 were sequentially hung from their leading socket 140, eachpreassembled parallel wire cable 50 may simply be pulled from the rack110. A worker need only locate an outermost leading socket 140 and beginremoving the corresponding preassembled parallel wire cable 50. Becausethe preassembled parallel wire cables 50 were sequentially hung, thelast hung cable is likely the first removed (LIFO). The worker merelydetaches and pulls the outermost leading socket 140 to sequentiallyremove the random cast 100 of loops of the corresponding preassembledparallel wire cable 50. As the leading socket 140 is pulled, thepreassembled parallel wire cable 50 extends and reduces the number ofthe random cast 100 of loops. When the preassembled parallel wire cable50 is fully extending to nearly its total length, the random cast 100 ofloops has been removed by extension. If the preassembled parallel wirecable 50 is too heavy or stiff for human extension, the leading socket140 may be mechanically pulled (such as by a forklift). Regardless, eachpreassembled parallel wire cable 50 is easily and quickly removed fromthe transportation rack 110.

FIG. 15 is a schematic illustrating straightening and reeling of theparallel wire cable 50, according to exemplary embodiments. Once thetension is applied to each individual wire (as illustrated withreference to FIG. 5) the parallel wire cable 50 may be straightened toreduce, or even remove, the memory cast. The parallel wire cable 50, forexample, may be fed into a series of rollers 170. Each roller 170 bearsdown on the parallel wire cable 50 by mechanical or hydraulic force. Theseries of rollers 170 reduces the memory cast in each individual wire46, thus producing a generally straight parallel wire cable 50. Thegenerally straight parallel wire cable 50 may then be wound or reeled ona reel 172 for later transport. Methods for straightening and reelingsteel cables are known, so this disclosure need not repeat known,conventional techniques.

Practical considerations arise. Because exemplary embodiments are somuch stronger than conventional cables, straightening and reelingoperations can become impractical for larger diameter wires. Forexample, the parallel wire cable 50, having a two-inch (2 in.) diameterof the individually tensioned wires, would require the reel 172 to havea diameter of over forty (40) feet. Such a large reel 172 is impracticalto load and transport. Moreover, straightening and reeling a two-inch (2in.) diameter cable 50 would require massive mechanical capabilities,which also greatly increases machinery costs and shop footprint.

Indeed, reeling practicality may be quantified. The inventor hasdiscovered that any reeling operation may be related to the overalldiameter of the parallel wire cable 50, according to the relationshipPracticality=f(D _(PWC)),where D_(PWC) is the diameter of the parallel wire cable 50. Thismeasure of practicality functionally relates the diameter D_(PWC) of theparallel wire cable 50 to the straightening and reeling operations forthe same parallel wire cable 50. The measure of practicality, in otherwords, relates the diameter D_(PWC) of the parallel wire cable 50 to thediameter D_(Reel) of the reel 172. Again using the two-inch (2 in.)outside, overall diameter, the reader realizes that

${\frac{D_{Reel}}{D_{PWC}} \approx 240},$meaning the diameter D_(Reel) of the reel 172 is about 240 times greaterthan the two-inch (2 in.) diameter D_(PWC) of the parallel wire cable50. The practicality function may be non-linear, as smaller diametercables may be straightened and reeled using existing machinery. Yet thelarger the diameter D_(PWC) of the parallel wire cable 50, then thelarger the diameter D_(Reel) of the reel 172 must be, due to non-linearincreases in yield strength of exemplary embodiments. Exemplaryembodiments, in short, are simply too strong for practical applicationof straightening and reeling machinery.

Straightening and reeling is perhaps best performed on the job site.Because exemplary embodiments are so strong, exemplary embodiments arepreferably transported with the memory cast, as this disclosureexplains. However, if straightening and reeling is desired, theseoperations are perhaps best suited for the installation site. The largerollers of the straightening operation may be set up at the installationsite, such as the location of a suspension bridge. Exemplary embodimentsmay thus be straightened with reduced transportation and handlingconcerns. Any reeling or coiling operation may also be performed onsite. However, given the large diameter reeling operation, roadwayproperty right of ways must be ensured.

FIG. 16 is a schematic illustrating an additional twisting operation ofthe parallel wire cable 50, according to exemplary embodiments. Even ifthe parallel wire cable 50 is reeled onto the reel 172, the reelingoperation must account for geometric considerations. Exemplaryembodiments are much stronger than conventional designs, for any kind ofbending, as the above paragraphs explain. As the parallel wire cable 50is reeled onto the reel 172, the parallel wire cable 50 is wrapped intoa circular coil. The outer ones 174 of the plurality 40 of wires arethus stretched, as the parallel wire cable 50 is reeled onto the reel172. Conversely, inner ones 176 of plurality 40 of wires are compressed,as the parallel wire cable 50 is reeled onto the reel 172. The outerwires 174, in other words, are subjected to tension and elongate inlength, while the inner wires 176 are subjected to compression andshorten in length. Both compression and elongation are greatest at smalldiameters of the reeling operation. This nearly simultaneous compressionand elongation of opposite sides can alter the parallel wireconfiguration. A solution is to introduce a rotational twist 180 of theparallel wire cable 50 with each rotation of the reel 172. That is, asthe parallel wire cable 50 is reeled onto the reel 172, the parallelwire cable 50 is also longitudinally twisted. Each 360 degree rotationof the reel 172 may require a 360 degree longitudinal twist 180 of theparallel wire cable 50. The longitudinal twist 180 helps maintain theparallel wire configuration of the plurality 40 of wires.

The reeling operation is thus greatly complicated. Because thelongitudinal twist 180 may be needed with each rotation of the reel 172,computer control is likely needed. The reeling operation is thus farmore expensive and complicated. The inventor has thus discovered afurther relation between the diameter D_(PWC) of the parallel wire cable50 and the drum diameter D_(Reel) of the reel 172. The drum diameterD_(Reel) of the reel 172 increases by the square of the diameter D_(PWC)of the parallel wire cable 50. The equipment costs are also similarlyrelated. In simple words, as the parallel wire cable 50 increases indiameter, the reeling operation squares in physical size and cost.Exemplary embodiments, again in short, are simply too strong forpractical application of reeling machinery for all but smallerdiameters.

FIG. 17 is a flowchart illustrating a method of transporting thepreassembled parallel wire cable 50, according to exemplary embodiments.The parallel wire cable 50 is preassembled creating the random cast 100of loops (Block 200). The leading socket 140 is sequentially first hungto the transportation rack 110 (Block 202). Second, the trailing socket142 is next hung to the transportation rack 110 (Block 204). Third, therandom cast 100 of loops is then hung to the rack 110 (Block 206). Therack 110 may be adjusted to suit the random cast 100 of loops (Block208). The rack is loaded onto commercial transport, such as trailer,ship, and/or barge (Block 210). The rack 110 is transported to aninstallation site (Block 212). The leading socket 140 is pulled toremove the preassembled parallel wire cable 50 (Block 214), which nearlysimultaneously reduces the random cast 100 of loops to full extension(Block 216).

While the exemplary embodiments have been described with respect tovarious features, aspects, and embodiments, those skilled and unskilledin the art will recognize the exemplary embodiments are not so limited.Other variations, modifications, and alternative embodiments may be madewithout departing from the spirit and scope of the exemplaryembodiments.

The invention claimed is:
 1. A method, comprising: manufacturing aparallel wire cable having a random cast of loops; determining a reelingpracticality using $\frac{D_{Reel}}{D_{PWC}},$ with the D_(PWC)representing a diameter of the parallel wire cable and the D_(Reel)representing a diameter associated with a reeling operation of theparallel wire cable; and in response to the reeling practicality,hanging the random cast of loops unreeled.
 2. A method of manufacturinga parallel wire cable, comprising: creating a random cast of loops inthe parallel wire cable by tensioning individual wires in the parallelwire cable; determining a reeling practicality using$\frac{D_{Reel}}{D_{PWC}},$ with the D_(PWC) representing a diameter ofthe parallel wire cable and the D_(Reel) representing a diameterassociated with a reeling operation for the parallel wire cable;determining the reeling operation is impractical based on the reelingpracticality; and in response to the reeling practicality beingimpractical, hanging the random cast of loops unreeled.